JP2010538881A5

JP2010538881A5 -

Info

Publication number: JP2010538881A5
Application number: JP2010525355A
Authority: JP
Filing date: 2008-09-18
Publication date: 2014-02-27
Anticipated expiration: 2028-09-18

Description

本発明の方法の好ましい実施形態では、連続気泡フォーム、特に網状フォームは、２０００〜７０００μｍの間の平均セルサイズを有し、好ましくは３０００μｍを超え、より好ましくは４０００μｍを超える平均セルサイズを有している。 In a preferred embodiment of the method of the invention, the open cell foam, in particular the reticulated foam, has an average cell size between 2000 and 7000 μm , preferably more than 3000 μm, more preferably more than 4000 μm. It is .

コア層１の連続気泡フォームは、ポリマー熱可塑性フォーム、例えばエチレン−プロピレン−ジエンゴムフォームであっても良く、ポリマー熱硬化フォーム、例えばポリウレタンフォームであっても良い。ポリマーフォームは、米国特許出願公開第２００６／００２６９７０号に記載されているような多くの種々の技術に従って製造できる。好ましい連続気泡フォームは、網状フォーム、特に網状ポリウレタンフォームである。好ましくは、連続気泡フォームは、２０００〜７０００μｍの間の平均セルサイズを有し、より好ましくは３０００μｍを超え、最も好ましくは４０００μｍを超える平均セルサイズを有している。 The open-cell foam of the core layer 1 may be a polymer thermoplastic foam, such as an ethylene-propylene-diene rubber foam, or may be a polymer thermoset foam, such as a polyurethane foam. The polymer foam can be produced according to a number of different techniques, such as those described in US Patent Application Publication No. 2006/0026970. Preferred open cell foams are reticulated foams, especially reticulated polyurethane foams. Preferably, the open-cell foam has an average cell size of between 2000～7000Myuemu, more preferably more than 3000 .mu.m, and most preferably has an average cell size of greater than 4000 .mu.m.

Claims

A method for manufacturing a foam product,
Providing at least a core layer (1) for the product, the core layer (1) comprising a flexible open cell foam, the open cell foam being the volume of the open cell foam; Having an open void occupying at least 90% of the
-Placing said core layer (1) between the lower mold surface (5) and the upper mold surface (9);
A liquid foamable composition based on a curable isocyanate with the core layer (1) maintained between the upper mold surface (9) and the lower mold surface (5). Allowing (7) to foam within the open void of the open-cell foam to produce another foam (4) that fills the open void;
-Removing the resulting foamed product from between the upper mold surface (9) and the lower mold surface (5),
The curable foamable formulation (7) is sprayed onto the core layer (1), and when the curable foamable formulation (7) reaches the core layer (1), a shear rate of 1 / s. Measured at 1000 mPa.s. having a dynamic viscosity of less than s, the core layer (1) was held in place when spraying the foamable formulation (7) onto the core layer (1), so that the sprayed The method wherein the foamable formulation (7) becomes at least partially penetrated into the open cell foam of the core layer (1) by gravity.

The method of claim 1, wherein the foamable formulation (7) is applied with an overfill degree of less than 100%.

The foamable composition (7) is, 20 and 100 kg / m ³ of which is formulated to produce a foam having a free rise density, according to claim 1 or 2 wherein.

The method according to any one of the preceding claims, wherein at least 80% by volume of the open voids of the open-cell foam is filled with the further foam (4).

The method according to claim 1, wherein the open-cell foam comprises a reticulated foam.

6. A method according to any one of claims 1 to 5, wherein the open cell foam has an average cell size between 2000 and 7000 [mu] m.

The method of claim 6, wherein the open-cell foam in the core layer has an average thickness at least equal to the average cell size in its uncompressed state.

8. A method according to any one of the preceding claims, wherein the open cell foam is made of a material that does not substantially absorb the foamable formulation.

When the foamable formulation (7) reaches the core layer (1), it is measured at a shear rate of 1 / s to 800 mPa.s. 9. A method according to any one of the preceding claims having a dynamic viscosity of less than s.

The core layer (1) is applied by spraying at least 75% by weight of the foamable formulation (7) onto the core layer (1) while the core layer (1) is held in the laying position. The method of any one of these.

The foamable compound (7) is sprayed on the first side of the core layer (1), and the first side is before the foamable compound (7) is sprayed on the core layer (1). 11. A method according to any one of the preceding claims, wherein the method is covered with at least one first cover layer (3).

The core layer (1) is covered with the first cover layer (3), the foamable compound (7) is sprayed onto the first cover layer (3), and the first cover layer (3) for the foamable formulation (7) so that the foamable formulation (7) can penetrate through the first cover layer (3) and into the core layer (1). 12. The method of claim 11, wherein the method is permeable.

The foamable formulation (7) is sprayed on a first side of the core layer (1), the core layer (1) having a second side opposite to the first side. The second side is covered with at least one second cover layer (2) having a layer that is impervious to the foamable formulation, the first side comprising a sandwich structure 13. A method according to any one of the preceding claims, covered with at least one first cover layer (3) to form.

The core layer (1) is draped and is draped on the lower mold surface (5), and the core layer (1) comprises the upper mold surface (9) and the lower mold surface. The method according to any one of claims 1 to 13, wherein the method is compressed between (5) and (5).

15. A method according to any one of claims 1 to 14, wherein the density of the open cell foam is less than 60 kg / m < ³ >.

16. A method according to any one of the preceding claims, wherein the open cell foam is stretchable and has an elongation of at least 100% as measured according to ISO 1798.

17. A method according to any one of the preceding claims, wherein the open cell foam has a CLD 40% hardness of less than 20 kPa, measured according to ISO 3386/1.

The core layer (1) is laid on the lower mold surface (5), and the curable foamable composition (7) is applied to the core layer on the lower mold surface (5). 18. A method according to any one of the preceding claims, wherein the method is sprayed on top of the core layer (1) during laying.

The method is a discontinuous method, and the foamed product is an upper mold part (8) that forms the upper mold surface (9) and a lower mold that forms the lower mold surface (5). Manufactured with a mold (6, 8) consisting of a part (6), the upper mold part (8) and the lower mold part (6) being relative to each other between a molding position and a demolding position In the method, the core layer (1) is laid on the lower mold surface (5) at the demolding position of the mold part (6, 8) and the foamable formulation The object (7) is sprayed on the core layer (1) laid on the lower mold surface (5), and the mold parts (6, 8) are moved to these molding positions, After the foamable formulation (7) has foamed, the mold parts (6, 8) are moved to their demolding positions and the manufactured foam product is moved into the mold. Retrieved from A method according to any one of claims 1 to 18.

19. The method according to any one of claims 1 to 18, wherein the method is a continuous method and the upper mold surface (9) and the lower mold surface (5) are formed by a conveyor system. Method.

21. A method according to any one of the preceding claims, wherein the lower mold surface (5) and / or the upper mold surface (9) has a three-dimensional shape.

The foamable formulation (7) is sprayed on a first side of the core layer (1), the core layer (1) having a second side opposite to the first side. The second side is covered with at least one second cover layer (2), the second cover layer (2) being applied to the lower mold surface (5) and laterally At least one insert (10) with a head portion (12) protruding into the core layer (1) either before or after attaching the core layer (1) to the lower mold surface (5), The projecting head portion (12) is inserted into a foamable compound (7) through a second cover layer (2) and inserted into a recess (11) formed in the lower mold surface (5). ) At a distance from the lower mold surface (5) so that it can enter between the protruding head portion (12) and the lower mold surface (5). It is the method according to any one of claims 1 to 21 maintained.

After the core layer (1) is applied to the lower mold surface (5), at least one insert (10) having a head portion (12) protruding laterally is formed on the core layer (1). ) Is inserted into a recess (11) formed in the lower mold surface (5), and the protruding head portion (12) is formed by the foamable compound (7) being the protruding head portion. Any one of claims 1 to 21, maintained at a distance from the lower mold surface (5) so as to be able to enter between (12) and the lower mold surface (5). The method according to claim 1.